Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
04/05
Intended use
The Festo Didactic Learning System has been developed and produced solely for
vocational and further training in the field of automation and technology. The
training company and/or instructor needs to ensure that trainees observe the safety
precautions specified in this workbook..
Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,
the training company and/or other parties, which may occur during the
use/application of this equipment set other than in a training situation and unless
such damages are caused by intention or gross negligence on the part of Festo
Didactic.
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005
Internet: www.festo-didactic.com
e-mail: did@festo.com
Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology package for electropneumatics (TP200) ________________________ 11
Training aims of Basic Level (TP201) _____________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Basic Level (TP201) _____________________________________ 17
Allocation of equipment and exercises ___________________________________ 21
Methodological help for the trainer ______________________________________ 23
Methodological structure of the exercises_________________________________ 25
Designation of equipment _____________________________________________ 26
Contents of the CD-ROM _______________________________________________ 27
Equipment set – Advanced Level (TP202) _________________________________ 29
Training aims – Advanced Level (TP202) __________________________________ 30
Part A – Exercises
Part B – Fundamentals
Part C – Solutions
Part D – Appendix
The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.
Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.
This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package TP200 is
comprised exclusively of electropneumatic control systems.
Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-
circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is
used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar =
800 kPa) can be used for compressed air supply.
The equipment set of Basic Level TP201 is used to construct all of the complete
control systems of the 12 problem definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook
• Electropneumatics
Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices, etc.).
The following advice should be observed in the interest of your own safety:
• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately.
• Do not switch on compressed air until tubing is securely connected.
• Caution!
Cylinders may advance automatically as soon as the compressed air is switched
on.
• Do not operate an electrical limit switch manually during fault finding (use a
tool).
• Observe general safety regulations.
• With electrical limit switches you need to distinguish between two designs
– Actuation from the left
– Actuation from the right.
• At high piston speeds, limit switches must be approached only in the designated
direction of the trip cam of the cylinder. Limit switches must not be actuated from
the front.
• Do not exceed the permissible working pressure (see data sheets).
• Only use extra-low voltage ≤ 24 V DC.
• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use
cables with jack plugs for the electrical connections.
• Pneumatic circuit assembly:
Connect devices using the silver-metallic plastic tubing of 4mm outer diameter,
plugging the tubing into the push-in fitting up to the stop; no need for securing!
• Releasing of push-in fitting:
The tubing can be released by pressing down the releasing ring (disconnection
under pressure is not possible!)
• Switch off compressed air supply and power supply prior to dismantling the
circuit.
• The mounting plates of the devices are equipped with mounting variants A to D:
Variant A, latching system
For lightweight non loadable devices (e.g. directional control valves). Simply clip
the device into the slot in the profile plate. Devices can be released by pressing
the blue lever.
Variant B, rotary system
Medium weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head bolts. Clamping and releasing is
effected by means of the blue knurled nut.
Variant C, screw system
For heavy loadable devices rarely removed from the profile plate (e.g. Start-up
valve with filter control valve). These devices are mounted by means of socket
head screws and T-head bolts.
Variant D, plug-in system
Lightweight non loadable devices with locking pins (e.g. indicating devices).
These devices are attached by means of plug-in adapters.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.
Training documentation
Seminars
Details of venues, dates and prices can be found in the current seminar planner.
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aims
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Training aims
This equipment set has been compiled for basic training in electropneumatic control
technology. It contains all the components required to meet the specifed training
aims and can be expanded in any way with other equipment sets. The profile plate
and a compressed air supply are required in addition.
Manifold 152896 1
Relay, 3-off
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
14 24 32 42
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
1M1
1 3
1M1
Description Symbol
1M1
5 1 3
1M1
1M1 1M2
5 1 3
1M1 1M2
Pressure sensor
Description Symbol
Single-acting cylinder
Double-acting cylinder
2
3
Manifold
Connection elements
Exercise 1 2 3 4 5 6 7 8 9 10 11 12
Equipment
Cylinder, single-acting 1 1 1 1
Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1
Pressure sensor 1
Relay 1 1 2 2 3 1 3 3 3 3
Manifold 1 1 1 1 1 1 1 1 1 1 1 1
• Training aims
The overall aim of this collection of exercises is the systematic design of circuit
diagrams and practical assembly of a control system on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
The detailed training aims are documented in the table. Actual individual training
aims are allocated to each problem and major training aims are shown in
brackets.
• Time required
The time required to work through a problem depends on the trainee’s prior
knowledge. Skilled workers in the engineering and electrical fields require
approximately 2 weeks. Technicians or engineers require approximately 1 week.
• Components of the equipment set
The book of exercises and equipment set are harmonised. For all 18 exercises
you only require the components of the equipment set of Basic Level TP201.
Each of the Basic Level exercises can be assembled on a profile plate.
• Representation
Abbreviated notation and motion diagrams are used for the representation of
motion sequences and switching statuses.
The CD-ROM supplied provides you with additional media. The contents of Part A –
Exercises and Part C – Solutions are stored in the form of pdf files.
Operating instructions Operating instructions are available for the various pieces of equipment of the
technology package to assist you in the use and commissioning of the equipment.
Data sheets The data sheets for the equipment of the technology package are available in the
form of pdf files.
Demo A demo version of the software package FluidSIM® Pneumatic is stored on the CD-
ROM. This version is suitable for the testing of the control systems developed.
Festo catalogue Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of
equipment. The representation and description of equipment in this form is intended
to illustrate how such equipment is represented in an industrial catalogue. You will
also find additional information here regarding the equipment.
FluidSIM® circuit diagrams FluidSIM® circuit diagrams are stored in this directory for all of the 12 exercises in
the technology package.
Industrial applications Photos and pictures are provided of industrial applications to enable you to
illustrate your own problem definitions. These can also be added to project
presentations.
Presentations Brief presentations are stored in this directory regarding the equipment of this
technology package. These presentations can for instance be used to create project
presentations.
Product information This directory provides you with the product information and data sheets of Festo
AG & Co. KG regarding the equipment of the technology package and is intended to
explain what information and data are provided for an industrial component.
Videos A number of videos of industrial applications complete the media for the training
package. Short sequences are shown of practice-related applications.
This Advanced Level equipment set has been compiled for further training in
pneumatic control technology. The two equipment sets (TP201 and TP202) comprise
the components required for the specified training aims and can expanded in any
way with other equipments sets of the Learning System for Automation and
Technology.
Part A – Exercises
Training aims • To familiarise yourself with the design and mode of operation of a single-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To be able to identify and draw various types of actuation of directional control
valves.
• To be able to explain and design an example of direct actuation.
Problem definition A sorting device is to be used to sort water samples according to the size of the
sample bottle. Design a control system whereby this process can be carried out.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Sorting device
Name: Date:
Description of function
Symbol 1:
Symbol 2:
Symbol 3:
Name: Date:
– Complete the individual symbols with the help of the corresponding component
descriptions.
Description Symbol
Name: Date:
An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated) or in the switching position (actuated). In the
normal position the valve can be open or closed.
– Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions. The single-acting cylinder shown is
controlled by an electrically actuated 3/2-way solenoid valve.
2 2
1M1 1M1
1 3 1 3
Name: Date:
– Describe the difference with the help of the following application: Electrical
actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.
Name: Date:
Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally open or normally closed contact or changeover
switch.
3 1 2 4
4 2 1
Description: Design/Function
Name: Date:
Electrically actuated directional control valves are switches with the help of
solenoids. Basically, these can be divided into two groups:
• Spring-return solenoid valves
• Double solenoid valves
– Describe the differences between the two groups with regard to function and
behaviour in the event of power failure.
Spring-return valve
Name: Date:
In order to prevent incorrect tubing up of directional control valves, the valve ports
(working and pilot lines) are identified in accordance with ISO 5599, both on the
valve itself and in the circuit diagram.
12
10
Name: Date:
– Complete the pneumatic and electrical circuit diagram for the sorting device.
1 3
+24 V 1
0V
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
• To be able to explain and design an example of direct actuation.
Problem definition In a water treatment system numerous pipes need to be opened or and closed by
means of shut-off devices. A test setup is to be used to find a possible means of
actuating the shut-off valve.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Shut-off device
Name: Date:
Differentiation is made between directly actuated and pilot actuated solenoid valves
with regard to the type of actuation of the valve piston.
– Compare these two valve types and describe the respective advantages and
disadvantages.
Name: Date:
14
82/84
Name: Date:
A valve symbol provides information regarding the function of the valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.
4 2
1M1
5 3
1
Name: Date:
Description of IP 65 classification
Name: Date:
Piston rod cylinders with linear action can be divided into two groups:
• Single-acting cylinders
• Double-acting cylinders
Symbol 1 Symbol 2
Name: Date:
– Complete the pneumatic and electrical circuit diagrams for the sorting device.
4 2
5 3
1
+24 V 1
0V
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
• To be able to explain and design an example of indirect actuation.
Problem definition In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids
are to be pressed onto the plastic pots.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid
to be pressed on.
2. Once the pushbutton is released, the pressing ram is to be returned into the
initial position.
Name: Date:
2 3
A1 A2 4 2 1
7 6
Name: Date:
Name: Date:
One or several contacts can be switched by a relay coil. Relays with normally closed,
normally open or changeover contact(s) are used depending on the function
required.
13 23 31 41
A1
A2 14 24 32 42
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
Name: Date:
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the lid press.
Name: Date:
+24 V 1 2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Problem definition Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed
using a hinged lid. The process is to be effected from two points.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and
to empty the bulk material from the container.
2. Once the pusbutton is released, the hinged lid closes.
Name: Date:
Note
By „conversion measures“ we understand the simplest of conversions such as the
sealing of working ports 2 or 4 using a blanking plug.
4 2
14
1M1
5 3
1
12
1M1
1
12
1M1
1 3
10
1M1
1 3
4 2
14
1M1
1 3
Name: Date:
The following valves are available for selection for the actuation of a single-acting
cylinder:
• A pilot actuated, spring return 3/2way solenoid valve with manual override,
• A pilot actuated, spring-return 5/2-way solenoid valve with manual override
Note
Apart from the cost of the valve, the above overall costs also include the cost of
installation, maintenance and storage for replacement parts.
Name: Date:
Note
0 means: Pushbutton not actuated, i.e. piston rod does not advance
1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
Logic symbol
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the operation of the
hinged lid.
Name: Date:
+24 V 1 2 3
12 14
K1
11
A1
K1 1M1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a double
solenoid valve.
Problem definition Packages are to be pushed from one conveyor to another via a diverting device.
Project task 1. Answer the questions and carry out the exercises regarding the training contents
listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Diverting device
Name: Date:
Two factors are to be considered regarding the question as to which valve type is to
be used for a particular application:
• Duration, i.e. time frame,
• Quantity or frequency
of required switching operations.
In order to utilise a directional control valve as efficiently as possible, you will need
to decide in each case whether the use
• of a double solenoid valve or
• a spring-return directional control valve
is more cost effective for the required application.
Application 1
The clamping cylinder of a milling device is to firmly hold in position a workpiece for
the duration of a milling operation (duration of approx. 10 min, 60 clamping
operations per day).
Application 2
The ejecting cylinder of a sorting device is to push defective workpieces from a
conveyor (duration of approx.1s, 600 ejecting operations per day).
Name: Date:
4 2
1M1 1M2
5 3
1
Name: Date:
– Calculate the current consumption of the valve coil 1M1 at a voltage supply of
24 V DC and a coil resistance of 48 Ω (Ohm).
+24 V 1
13
S1
14
1M1
0V
Name: Date:
– Would the current consumption in 1M1 be the same, higher or lower if the above
valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the diverting device.
Name: Date:
+24 V 1 2 3 4
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Problem definition Wooden boards are to be pushed from a stacking magazine into an assembly device.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Stacking magazine
Name: Date:
Cylinder
Valves
Valve coils
Relay
Indicating devices
Name: Date:
Name: Date:
Limit switches can be actuated in different ways, via the function of a normally
closed or normally open contact or changeover switch and, in the normal position of
the system, can be either actuated or unactuated.
Name: Date:
+24 V 10 11 12 13 14 15 16 17 18 19
...
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
11 11 11 11 11 11 11 11 31 31
12 14
K1
11
22 24 22 24 22 24 22 24 32 34 32 34
K9 K6 K7 K8 K9 K8
21 21 21 21 31 31
A1 A1 A1 A1
K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2
...
0V
K6
K9
Name: Date:
Another method of recording the allocated contact sets of a relay can be seen in the
electrical circuit diagram below.
+24 V 1 2 3 4 5 6 7 8 9 10 11 25 27
21 12 14 22 24 32 34
NA K11 K11 K11
EMERGENCY 22 11 21 31
STOP 12 13 16 17 18 19 20 21 22 23 24 26
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34 22 24
1B1 1B2 2B1 2B2 13
K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
S1
11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
Start 14
12 14
K1
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
21 21 21 21 21 41 41 41 31
0V 12 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 .11 11 14 .12 11 14 .14 11 14 .18 11 14 .16 11 14 .12 11 14 .13 11 14 .15 11 14 .17 11 14 .19 11 14 .21
22 22 22 22 22 22 22 22 22 22 22
21 24 .25 21 24 .20 21 24 21 24 .27 21 24 21 24 21 24 .14 21 24 .16 21 24 .18 21 24 .20 21 24 .12
32 32 32 32 32 32 32 32 32 32 32
31 34 .27 31 34 31 34 31 34 31 34 31 34 31 34 .22 31 34 .23 31 34 .24 31 34 .26 31 34 .26
42 42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 .22 41 44 .23 41 44 .24 41 44
Name: Date:
Relay K9
Relay K10
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the stacking magazine.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
5 3
1
Name: Date:
+24 V 1 2 3 4
12 14 12 14
K1 K2
11 11
A1 A1
K1 K2
A2 A2
0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Problem definition Packages are to be transported on a conveyor past workstations. The packages can
be diverted by means of deflectors.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Name: Date:
The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a
diameter of 8 mm. The frictional losses within the cylinder are 10 %.
– Calculate the effective piston force in the advance and return stroke at an
operating pressure of 6 bar (600 kPa).
Advance stroke
Return stroke
Name: Date:
Max. Operating
voltage
Name: Date:
Fundamentals: Sheet 3 of 3
Note
0 means: Pushbutton not actuated, i.e. piston rod not advancing
1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
Logic symbol
Name: Date:
– Configure the pneumatic circuit diagram and design the electrical circuit diagram
for the feeding device.
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5
A1 A1
K1 K2 K3 1M1 1M2
A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with logic functions and to be able to design these
• To be able to explain and design electrical latching circuits with dominant switch-
off signal
Problem definition Wooden boards are to be manually placed onto a sliding platform. The boards are to
be pushed under a belt sanding machine by means of a pneumatic drive.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile the equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Sliding platform
Name: Date:
The actuation of the pushbutton must be stored if the piston rod of a cylinder is to
also advance if the pushbutton is only briefly actuated. This signal storage can be
effected either in the power section or in the signal control section of a circuit.
– Describe how signal storage is devised in the power section or in the signal
control section respectively.
Name: Date:
Name: Date:
S1 P1
Function table
Logic symbol
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the sliding platform.
4 2
5 3
1
Name: Date:
+24 V 1 2 3
A1
K1 1M1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with different types of end position control and to be able
to select a suitable type.
• To familiarise yourself with latching circuits of different characteristics.
Problem definition Packages are to be transferred from one conveyor belt to another via a diverting
device using reciprocating strokes. Once switched on, the device is to run
continuously and only be switched off via a stop signal.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile the equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Name: Date:
A latching relay circuit is required in order to store a signal in the signal control
section.
+24 V 1
13
S1
14
A1
K1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
– Complete the electrical circuit diagram below so that the self-latching loop is
reliably cancelled via the actuation of a pushbutton S2.
+24 V 1
13
S1
14
A1
K1
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
– Complete the table and enter the behaviour of the respective valve.
Valve position unchanged/valve is actuated/valve switches to normal position
Power failure
Name: Date:
The function of limit switches and proximity sensors is to acquire information and to
transmit this for signal processing.
These include:
Mechanical position switches (limit switches), magnetic proximity sensors (reed
switches), optical proximity sensors, capacitive proximity sensors, inductive
proximity sensors
Designation Symbol
BN
BK
BU
BN
BK
BU
BN
BK
BU
2 4
BN
BK
BU
Name: Date:
– Design the pneumatic and electrical circuit diagram for the diverting device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5 6 7 8
13 12 14
S1 K1
14 11
31
S2
32
A1
K1 1M1 1M2
A2
0V 12
11 14
22
21 24
32
31 34
42
41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Problem definition Small mounting blocks are to be stamped during the production of door frames.
These blocks are to be stamped by means of a stamping device.
Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
Positional sketch
Stamping device
1. The pressing of a pushbutton is to cause the stamping device to advance and the
workpiece to be stamped.
2. The stamping tool is to return into the initial position once the stamping pressure
is obtained.
Name: Date:
In contrast with limit switches proximity sensors are switched contactlessly and
without an external mechanical actuating force.
– Describe the design and function of a magnetic proximity sensor (reed switch).
BN
BK
BU
Name: Date:
As regards polarity there are two different designs of electronic proximity sensors,
i.e. PNP or NPN.
PNP NPN
Name: Date:
Name: Date:
Pressure sensors can be divided into two groups whereby differentiation is made
between:
• Pressure sensors with mechanical contact (mechanical principle of action)
• Pressure sensors with electronic switching
(electronic principle of action)
– Describe the purpose and function of the pressure sensor shown below.
Name: Date:
– Choose which proximity sensors meet the specified requirements and explain
your reasons for this.
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the stamping device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5 6 7 8
A1 A1 A1
K1 K2 K3 1M1 1M2
A2 A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
• To be able to realise a sequence control using two cylinders.
Problem definition Stacks of roof tiles are to be strapped with a band and then transported to a pallet
loading station, where they are to be transferred onto Euro pallets.
Parameters • Adjust the one-way flow control valve so that both cylinders retract at identical
speed.
Positional sketch
Name: Date:
1 2 3 4=1
1A1
0
1
2A1
0
Displacement-step diagram
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the pallet loading
station.
1A1 2A1
2 2 1
1V1 4 2 2V1 2
5 3 1 3
1
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
BK BK
BU BU
A1 A1 A1
1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 11 14 11 14
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list
Training aims • To be able to identify and eliminate faults in simple electropneumatic control
systems.
Problem definition The pallet loading station stops during continuous operation. A fault has occurred
and must be eliminated. Thereafter the pallet loading station is to be re-started.
Project task 1. Describe the behaviour of the control system. Compare this with the correct
control system behaviour. Use the displacement-step diagram to assist you.
2. Localise potential causes of the fault with the help of the pneumatic and
electrical circuit diagrams.
3. Find the fault in the control system and eliminate it.
4. Re-start the control system.
Positional sketch
Name: Date:
1A1 2A1
1B2 2B2
2 2 1
1V1 4 2 2V1 2
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
A cable break occurs at the areas marked in the circuit shown below.
– Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Name: Date:
– Create the displacement-step diagram with the help of the documentation given
out.
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal
Displacement-step diagram
Name: Date:
Determine the ACTUAL status of the system with the help of the following
documentation:
• Positional sketch with problem description
• Graphic representation
Components Time
Step
1 2 3 4 5 6 7 8 9 10
Designation Identification Signal
Displacement-step diagram
Name: Date:
You have marked the area where a fault occurs in the diagram of the worksheet
‘REFERENCE/ACTUAL comparison.
– Describe the process up the point where the station or system stops.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Name: Date:
Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.
– Enter all the possibilities and indicate components at the start and end of the
tubing connection in order to ensure clear identification.
Potential faults
Name: Date:
Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.
Potential faults
Name: Date:
Investigate the potential causes of errors you have found in the pneumatics.
• Use the same fault numbering that you have used for the worksheet ‘Definition
of faults – pneumatic.
• Document the procedure used to investigate the tubing connections.
Name: Date:
• Use the same fault numbering that you have used in the worksheet ‘Definition of
faults - electrics’.
• Document the procedure you have used to check the line connection.
Name: Date:
Once you have localised the failure location, your procedure for the elimination of
the fault must be documented on this worksheet.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Note
In the event of the system not fulfilling the intended function return to the first
worksheet and repeat the fault finding.
Name: Date:
Once you have identified, localised and eliminated the fault, re-start the system in
accordance with the required status.
Reset the specified required times.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Part C – Solutions
Name: Date:
Description: Function
Symbol 1
Single-acting cylinder, return spring in piston chamber, return stroke via compressed air, forward
stroke via return spring.
Function
The piston rod of this single-acting cylinder is moved into the retracted end position by means of
switching on the compressed air. Once the compressed air is switched off the piston reverses into the
forward end position via a return spring in the piston chamber (2 operating positions).
Symbol 2
Single-acting cylinder, return spring in piston chamber, forward stroke via compressed air, return
stroke via return spring
Function
The piston rod of the single-acting cylinder is moved into the forward end position by means of
switching on the compressed air. Once the compressed air is switched off the piston reverses into the
retracted end position (2 operating positions).
Symbol 3
Pneumatic semi-rotary drive (swivelling drive), with limited swivel range
Function
This semi-rotary drive is double-acting and is reversed by means of alternating connection of
compressed air (2 operating positions).
Name: Date:
– Complete the individual symbols with the help of the corresponding component
descriptions.
Description Symbol
Name: Date:
An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated), or in the switching position (actuated). In the
normal position the valve can be closed or open.
– Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions: The single-acting cylinder shown is
controlled by one of the represented 3/2-way solenoid valves respectively.
2 2
12 10
1M1 1M1
1 3 1 3
Description: Description:
3/2-way solenoid valve, normally closed 3/2-way solenoid valve, normally open
The solenoid valve used is reversed via the The solenoid valve used is reversed by applying
application of voltage at the solenoid coil; flow is voltage at the solenoid coil; port 1 (and
released from pressure port 1 to working port 2. consequently flow) is closed. If the signal is
When the signal is cancelled, the valve is cancelled the valve is returned to the initial
returned to the initial position via a return spring; position via a return spring and flow is released
pressure port 1 (and consequently flow) is from pressure port 1 to working port 2. If the
closed. If the solenoid coil of the directional solenoid coil of the directional control valve is
control valve is de-energised, the cylinder de-energised, the cylinder chamber is
chamber is exhausted via the directional control pressurised via the directional control valve and
valve (exhaust port 3), and the piston rod is the piston rod is advanced. If the solenoid coil is
retracted. If the solenoid coil is energised, the energised the directional control valve switches
directional control valve switches. The cylinder and the cylinder chamber is exhausted via the
chamber is pressurised and the piston is directional control valve (exhaust port 3),
advanced. If the solenoid coil is de-energised, causing the piston rod to retract. The valve
the valve reverses. The cylinder chamber is reverses if the solenoid coil is de-energised. The
exhausted and the piston rod retracts. cylinder chamber is pressurised and the piston
Consequently the motion sequence is: 1A1+ 1A1- rod advances.
Consequently the motion sequence is: 1A1- 1A1+
Name: Date:
Current flows through the solenoid coil of the In the case of indirect control, current flows
valve if the pushbutton is actuated. The solenoid through a relay coil if a pushbutton is actuated.
is energised and the valve switches into the The relay contact closes and the valve switches.
actuated position. The switching position is retained for as long as
The current flow is interrupted if the pushbutton current flows through the solenoid or relay coil
is released. The solenoid is de-energised and the (in the case of self-latching loops also after the
directional control valve returns to the initial pushbutton is released). The relay is de-
position. energised if the current flow is interrupted via
the relay coil and the valve switches into the
initial position.
More complex, indirect actuation is always used
if the control circuit and primary circuit operate
using different voltages, the current through the
coil of the directional control valve exceeds the
permissible current for the pushbutton, if several
valves are switched using one pushbutton or
extensive logic functions are required between
the signals of various pushbuttons.
Name: Date:
Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally closed contact, normally open contact or
changeover switch.
3 1 2 4
4 2 1
Description: Design/function
Symbol
Pushbutton with normally open function
Function
With a pushbutton, the selected switching position is only retained for as long as it is actuated. The
pushbutton shown performs the function of a normally open contact. In the case of a normally open
contact, the circuit is interrupted in the normal position of the pushbutton, i.e. in the unactuated state.
Actuation of the switching stem causes the circuit to be closed and current to flow to the consuming
device. Once the switching stem is released, the pushbutton returns to the normal position as a result
of the spring force, thereby interrupting the circuit.
Symbol
Detent switch with normally closed contact
Function
In the case of a detent switch both switching positions are mechanically locked. A switching position is
therefore always retained until the switch is re-actuated. The detent switch shown performs the
function of a normally closed contact. With a normally closed contact the circuit is closed in the normal
position of the detent switch due to the spring force. Actuation of the detent switch causes the circuit
to be interrupted and renewed actuation closes the circuit again.
Symbol
Pushbutton with changeover function
Function
In the case of this pushbutton, the selected switching position is retained only for as long as this is
actuated. The pushbutton shown performs the function of a changeover switch, where the functions of
a normally closed and normally open contact are combined in one device. A switching action causes
one circuit to be closed and another circuit to be opened. Both circuits are briefly interrupted during
switching.
Name: Date:
Electrically actuated directional control valves are switched with the help of
solenoids and can basically be divided into two groups:
• Spring return valves
• Double solenoid valves
– Describe how these two groups differ with regard to function and behaviour in
the event of a power failure.
Spring return valve The actuated switching position is maintained only for as long as
current flows through the solenoid coil. The normal position is
clearly defined by the return spring. In the event of a power failure
the valve switches to the normal position via the spring and this
may trigger dangerous machine movements,
e.g. causes the piston rod of a pneumatic cylinder to move into
the initial position and release the clamping of a workpiece.
Double-solenoid valve Switching of the valve merely requires a brief signal; due to the
static friction, the last assumed switching position is retained
even in the de-energised state. All solenoid coils are de-energised
in the normal position and the normal position cannot be clearly
defined. In the event of a power failure, the valve retains its last
switching position; no dangerous movements are triggered,
e.g. the piston rod of a pneumatic cylinder maintains its operating
position and retains a workpiece.
Name: Date:
Pilot line, with pilot actuated or pneumatically actuated directional control valves;
12
Function on actuation: Connection of supply port 1 and working port 2
Pilot line, with pilot actuated or pneumatically actuated directional control valves;
10
Function on actuation: Closing of supply port 1
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the sorting device.
1A1
1V2 2
1
1V1 2
1M1
1 3
0Z2
0Z1
1
2
3
Name: Date:
+24 V 1
13
S1
14
1M1
0V
Name: Date:
Initial position
The cylinder is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact), causes the solenoid coil 1M1 of
the 3/2-way solenoid valve 1V1 to be energised. The valve 1V1 reverses and cylinder
1A1 advances.
Steps 2-3
As soon as pushbutton S1(normally open contact) is no longer actuated, the coil
1M1 is de-energised, the valve 1V1 is returned into the initial position via the return
spring, the cylinder 1A1 is exhausted and the spring returns the cylinder into the
retracted end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, single-acting
1 Manifold
Equipment list
Name: Date:
– Compare these two valve types and describe the respective advantages and
disadvantages.
Flow is releases to the consuming device via Flow to the consuming device is switched via the
the armature of the solenoid. In order to obtain main stage. The valve piston is moved via an air
a sufficient cross section of opening, a duct from pressure port 1.
comparably large armature is required. This This only requires a low flow so that a
consequently requires a powerful return spring comparatively small armature with minimal
and the solenoid to generate a high force. It is actuating force can be used. A minimum supply
therefore of a large design with high power pressure is required in order to actuate the piston
consumption. against the spring force.
Compared to a directly actuated valve, the solenoid
can be configured in a small design and the power
consumption and heat emission is thus reduced.
Name: Date:
Power line, with pilot actuated or pneumatically actuated directional control valves
14
Function on actuation: Connection of supply port 1 and working port 4
Pilot line, with pilot actuated or pneumatically actuated directional control valves
82/84
Function on actuation: Auxiliary pilot air exhausting
Name: Date:
A valve symbol provides information regarding the function of the valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.
4 2
1M1
5 3
1
Pilot actuated 5/2-way solenoid valve, with manual override, with spring return
Mode of operation:
In the normal position, the piston is positioned at the lefthand stop, the ports 1 (supply port) and 2
(working port), as well as the ports 4 (working port) and 5 (exhaust port) are connected. If the
solenoid coil is energised, the valve piston moves up to the righthand stop. In this position, ports 1
and 4 as well as 2 and 3 (exhaust port) are connected (the designation of the internal line of the pilot
control is 14; function on actuation: Connection of supply port 1 and working port 4).
If the solenoid is de-energised, the valve piston switches back into the normal position due to the
spring force and the pilot air is exhausted. In the de-energised state the valve can be switched by
means of a manual override.
Name: Date:
Description: IP 65 classification
In accordance with DIN-VDE 470-1, the protection classification code is composed of the two letters IP
(for “International Protection”) and two digits.
The first digit indicates the scope of protection against the ingress of dust or foreign objects and the
second digit the scope of protection against the penetration of humidity or water.
Protection class IP 65 therefore means protection against the ingress of dust .
(i.e. complete protection against contact with energised or internally moving parts, protection against
the ingress of dust) and hose-water (i.e. strong jets of water aimed from any direction against the
housing/enclosure must not have any harmful effect).
Name: Date:
Piston rod cylinder with linear action can be divided into two groups:
• Single-acting cylinders
• Double-acting cylinders
Symbol 1 Symbol 2
Symbol 1
Double-acting multi-position cylinder; reversal via alternating supply of compressed air. By series
connecting two cylinders of identical piston diameter and different stroke length, it is possible to
approach three positions. The third position can be approached directly or via the second
intermediate position from the first position. However, to do so the subsequent cylinder stroke must
always be greater than the previous stroke. With the return stroke, an intermediate position is only
possible with the appropriate actuation (3 working positions). The shorter stroke length is half of the
longer one.
Symbol 2
Double-acting cylinder, reversal via alternating supply of compressed air, adjustable end position
cushioning (2 working positions)
Cushioning is used in the end position if large loads are to be moved by a cylinder. Prior to reaching
the end position, a cushioning piston interrupts the direct exhaust path of air to atmosphere. The
restricted exhaust air causes the piston speed to be reduced during the last part of the stroke travel.
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the shut-off device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1
+24 V 1
13
S1
14
1M1
0V
Name: Date:
Initial position
The cylinder is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1(normally open contact) causes the solenoid coil 1M1 of
the 5/2-way solenoid valve 1V1 to be energised and the valve 1V1 to reverse. The
piston side of cylinder 1A1 is now filled with compressed air whilst the piston rod
side is exhausted. Cylinder 1A1 advances.
Steps 2-3
As soon as pushbutton S1 (normally open contact) is no longer actuated, the coil
1M1 is de-energised and the valve 1V1 is returned to the initial position again via
the return spring. The piston side of cylinder 1A1 is exhausted whilst the piston rod
side is filled with compressed air. The cylinder returns into the retracted end
position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
1 Manifold
Equipment list
Name: Date:
Relays form part of the components of the electrical signal control section. The main
components are:
• Coil with core
• Coil winding
• Contact set
• Return spring
• Armature
• Terminal lugs
2 3
A1 A2 4 2 1
7 6
Name: Date:
Name: Date:
One or several contacts can be switched by a relay coil. Depending on the required
function, a relay with normally open, normally closed or changeover contact(s) is
used.
Name: Date:
• Signal multiplication
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the lid press.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1
Name: Date:
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised, the changeover contact K1 (connected in the form of a normally open
contact) also closed and the solenoid coil 1M1 of the 5/2-way valve 1V1 is
energised. The valve 1V1 reverses and causes the rear chamber of cylinder 1A1 to be
filled with compressed air whilst the front chamber if exhausted. Cylinder 1A1
advances.
Steps 2-3
As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K1 is
de-energised and the changeover contact K1(connected in the form of a normally
open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1
to be returned into the initial position via the return spring. The rear chamber of
cylinder 1A1 is exhausted whilst the front chamber is filled with compressed air. the
cylinder returns into the retracted end position.
Name: Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 1 of 2
Indirect actuation does of course function equally with a 3/2-way solenoid valve and
single-acting cylinder.
1A1
1V2 2
1V1 2
1M1
1 3
Name: Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 2 of 2
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Create the equipment list by entering the required equipment in the table below.
Quantity Designation
1 Cylinder, double-acting
1 Relay
1 Manifold
Equipment list
Name: Date:
Note
By the term „conversion measures“ we understand the simplest of conversions,
such as the closing of working ports 2 or 4 using a blanking plug.
4 2
14
1M1
5 3
1
Name: Date:
Note
Apart from the costs of the actual valve, the above mentioned overall costs of a
valve also include the costs for installation, maintenance and storage of
replacement parts.
Pilot actuated, spring As can be seen from question 1, the 5/2-way solenoid valve has a broad
return 5/2-way spectrum of possible applications. In practice this means that only one valve
solenoid valve with type is required for different requirements or applications. This in turn
manual override means a considerable cost reduction thanks to more alternatives when it
comes to the procurement of the valve and storage of replacement parts.
The maintenance of different valves entails considerable higher expenditure
compared to maintaining a single valve type. A 3/2-way valve can only
actuate single-acting cylinders whereas a 5/2-way valve can actuate single-
acting and double-acting cylinders. This is why the choice should be a 5/2-
way solenoid valve. The fact that the costs of a 3/2-way solenoid valve are
usually 5 % below that of a 5/2-way double solenoid valve is immaterial in
view of the above mentioned advantages.
Name: Date:
Fundamentals Sheet 3 of 3
Triggering the advance of the cylinder piston rod is to be possible using two
pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve
coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position
and the piston rod advances. If both pushbuttons are released, the valve switches
into the initial position and the piston rod retracts.
Note
0 means: Pushbutton not actuated, i.e. piston rod does not advance
1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
S1 <=1 1M1
S2
Logic symbol
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the hinged lid.
1A1
1V2 2
1V1 4 2
1M1
5 3
1
Name: Date:
+24 V 1 2 3
13 13 12 14
S1 S2 K1
14 14 11
A1
K1 1M1
A2
0V 12
11 14 .3
22
21 24
32
31 34
42
41 44
Name: Date:
Initial position
In the initial position cylinder 1A1 is in the forward end position and the rear cylinder
chamber is filled with compressed air.
Steps 1-2
Actuation of pushbutton S1 or pushbutton S2 (both in the form of normally open
contacts), causes the relay K1 to be energised, the changeover contact K1
(connected in the form of a normally open contact) closes and the solenoid coil 1M1
of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and the rear chamber
of cylinder 1A1 is exhausted; the spring presses the cylinder into the retracted end
position.
Steps 2-3
As soon as the pushbutton S1 or S2 (both in the form of normally open contacts), are
no longer pressed, the relay K1 is de-energised, the changeover switch K1
(connected in the form of a normally open contact) opens. This causes the coil 1M1
to be de-energised and the valve 1V1 to be returned into the initial position via the
return spring. The rear chamber of cylinder 1A1 is filled with compressed air and the
cylinder returns into the forward end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Create the equipment list by entering the required equipment in the table below.
Quantity Description
1 Cylinder, single-acting
1 Relay
1 Manifold
Equipment list
Name: Date:
Two factors are to be taken into consideration with regard to the question as to
which valve type is to be used for a particular application:
• Duration, i.e. time frame,
• Quantity or frequency
of required switching operations.
In order to utilise a directional control valve as efficiently as possible, you will need
to decide in each case whether
• a double-solenoid valve or
• a spring-return directional control valve
is more cost effective for the required application.
Application 1
The clamping cylinder of a milling device is to firmly hold in position a workpiece for
the duration of a milling operation (duration of approx. 10 min, 60 clamping
operations per day).
Double solenoid An applied signal needs to be stored for lengthy switching operations. In the
valve case of double solenoid valve this occurs via static friction and with spring
return directional control valves via continuously energising the solenoid
coil. Clamped workpieces must not be released in the event of EMERGENCY-
STOP, hence the use of spring-return solenoid valves is not permissible in
this case.
Application 2
The ejecting cylinder of a sorting device is to push defective workpieces from a
conveyor (duration of approx. 1s, 600 ejecting operations per day).
Spring-returned For short switching operations an applied signal does not need to be stored.
solenoid valve Spring-return solenoid valves have the advantage: Only one valve coil needs
to be actuated, i.e. energised to switch the valve.
Name: Date:
4 2
1M1 1M2
5 3
1
Name: Date:
– Calculate the current consumption of the valve coil 1M1 at a voltage supply of
24 V DC and a coil resistance of 48 Ω (Ohm).
+24 V 1
13
S1
14
1M1
0V
U 24V
I= = = 0.5 A
R 48Ω
Name: Date:
– Would the current consumption in S1 be the same, higher or lower if the above
valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the diverting device.
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4
13 13 12 14 12 14
S1 S2 K1 K2
14 14 11 11
A1 A1
K1 K2 1M1 1M2
A2 A2
0V 12 12
11 14 .3 11 14 .4
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Name: Date:
Initial position
In the initial position, cylinder 1A1 is in the retracted end position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised, the changeover contact K1 (connected in the form of a normally open
contact) to close and the solenoid coil 1M1 of the 5/2-way double solenoid valve
1V1 to be energised. The valve 1V1 reverses and the rear chamber of cylinder 1A1 is
filled with compressed air whilst the front chamber is exhausted. Cylinder 1A1
advances.
Steps 2-3
Actuation of pushbutton S2 (normally open contact) causes the relay K2 to be
energised and the changeover contact K2 (connected in the form of a normally open
contact) to be closed. This causes the coil 1M2 to be energised and the valve 1V1 to
return into the initial position. The front chamber of the cylinder 1A1 is filled with
compressed air whilst the rear chamber is exhausted. The cylinder 1A1 returns into
the retracted end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
2 Relay
1 Manifold
Equipment list
Name: Date:
Cylinder X
Valves X
Valve coils X X
Relay X
Indicating devices X
Name: Date:
To detect the forward and retracted end positions of the piston rod of drive cylinders
Name: Date:
Limit switches can be actuated in different ways, via the function of a normally
closed or normally open contact or changeover switch and, in the normal position of
the system, can be either actuated or unactuated.
Name: Date:
– Create the logic element table for the relays K6 and K9.
+24 V 10 11 12 13 14 15 16 17 18 19
...
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 32 34 32 34
K5 K6 K2 K7 K4 K8 K3 K9 K6 K7
11 11 11 11 11 11 11 11 31 31
12 14
K1
11
22 24 22 24 22 24 22 24 32 34 32 34
K9 K6 K7 K8 K9 K8
21 21 21 21 31 31
A1 A1 A1 A1
K6 K7 K8 K9 1M1 2M1
A2 A2 A2 A2
...
0V
11
12
18
10 17
18
Name: Date:
Another method of recording the allocated contact sets of a relay can be seen in the
electrical circuit diagram below.
+24 V 1 2 3 4 5 6 7 8 9 10 11 25 27
21 12 14 22 24 32 34
NA K11 K11 K11
EMERGENCY 22 11 21 31
STOP 12 13 16 17 18 19 20 21 22 23 24 26
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14 22 24 12 14 32 34 32 34 32 34 32 34 22 24
1B1 1B2 2B1 2B2 13
K5 K6 K7 K4 K8 K3 K9 K1 K10 K6 K7 K8 K9 K3
S1
11 11 11 11 11 11 11 11 21 11 31 31 31 31 21
Start 14
12 14
K1
11
22 24 22 24 22 24 22 24 22 24 42 44 42 44 42 44 32 34
K10 K6 K7 K8 K9 K7 K8 K9 K10
21 21 21 21 21 41 41 41 31
0V 12 12 12 12 12 12 12 12 12 12 12
1A1+ 2A1+ 2A1- 1A1-
11 14 .11 11 14 .12 11 14 .14 11 14 .18 11 14 .16 11 14 .12 11 14 .13 11 14 .15 11 14 .17 11 14 .19 11 14 .21
22 22 22 22 22 22 22 22 22 22 22
21 24 .25 21 24 .20 21 24 21 24 .27 21 24 21 24 21 24 .14 21 24 .16 21 24 .18 21 24 .20 21 24 .12
32 32 32 32 32 32 32 32 32 32 32
31 34 .27 31 34 31 34 31 34 31 34 31 34 31 34 .22 31 34 .23 31 34 .24 31 34 .26 31 34 .26
42 42 42 42 42 42 42 42 42 42 42
41 44 41 44 41 44 41 44 41 44 41 44 41 44 41 44 .22 41 44 .23 41 44 .24 41 44
Name: Date:
Fundamentals Sheet 6 of 6
Current path 20 X
Current path 24 X
Current path 26 X
Current path 21 X
Current path 26 X
Name: Date:
1A1
1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4
13 2 4 12 14 12 14
S1 1B2 K1 K2
14 1 11 11
A1 A1
K1 K2 1M1 1M2
A2 A2
0V 12 12
11 14 .3 11 14 .4
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Name: Date:
Initial position
Cylinder 1A1 is in the retracted and position in the initial position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised; the changeover contact K1 (connected in the form of a normally open
contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1
is energised. The valve 1V1 reverses. The rear chamber of the cylinder 1A1 is filled
with compressed air whilst the front chamber is exhausted. The cylinder 1A1
advances.
Steps 2-3
Once the cylinder has reached its forward end position, the piston rod actuates the
electrical limit switch 1B2. The changeover switch 1B2 (connected in the form of a
normally open contact) closes and the relay K2 is energised. The changeover contact
K2 (connected in the form of a normally open contact) closes and the solenoid coil
1M2 is energised. The valve 1V1 reverses into the initial position again.
The front chamber of the cylinder 1A1 is filled with compressed air whilst the rear
chamber is exhausted. The cylinder returns into the retracted end position again.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
2 Relay
1 Manifold
Equipment list
Name: Date:
– Calculate the effective piston force in the advance and return stroke at an
operating pressure of 6 bar (600 kPa).
To be calculated Solution
Name: Date:
Max. Operating A maximum operating voltage of 24 volts is calculated on the basis of the
voltage formula
V2
P = V ⋅ I = I2 ⋅ R =
R
Name: Date:
Fundamentals Sheet 3 of 3
Note
0 means: Pushbutton not actuated, i.e. piston rod not advancing
1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
S1 & 1M1
S2
Logic symbol
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5
13 2 4 2 4 12 14 12 14
S1 1B1 1 B2 K1 K3
14 1 1 11 11
12 14
K2
11
A1 A1
K1 K2 K3 1M1 1M2
A2 A2
0V 12 12 12
11 14 .4 11 14 .4 11 14 .5
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Initial position
The cylinder 1A1 is in the retracted end position in the initial position.
If the cylinder is in the retracted end position, then the electrical limit switch 1B1 is
actuated (changeover contact, connected in the form of a normally open contact)
and the changeover switch 1B1 closed and the relay K2 energised.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energise. The changeover contact K1 (in the form of a normally open contact) closes
and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised.
The double solenoid valve 1V1 reverses. The piston end of cylinder 1A1 is filled with
compressed air whilst the piston rod end is exhausted and cylinder 1A1 advances.
As soon as the cylinder 1A1 moves out of the retracted end position, limit switch 1B1
is no longer actuated and the changeover switch 1B1 opens. This causes the
normally open contact K2 to open and the solenoid coil 1M1 to be no longer
energised. However the double solenoid valve still remains in the righthand
switching position.
Steps 2-3
Once the cylinder reaches its forward end position, the piston rod actuates the
electrical limit switch 1B2 (changeover contact, connected in the form of a normally
open contact). The changeover switch 1B2 closes and the relay K3 is energised. The
closing of the changeover contact K3 (connected in the form of a normally open
contact), also causes the solenoid coil 1M2 to be energised. The
valve 1V1 reverses.
The piston rod chamber of cylinder 1A1 is filled with compressed air whilst the
piston end is exhausted. The cylinder moves into the retracted end position again.
As soon as the electrical limit switch 1B2 is no longer actuated (changeover contact,
connected in the form of a normally open contact), the relay K3 is de-energised and
the changeover contact K3 (connected in the form of a normally open contact)
opens. This also causes the coil 1M2 to be de-energised. The cylinder remains in the
retracted end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
3 Relay
1 Manifold
Equipment list
Name: Date:
The actuation of the pushbutton must be stored if the piston rod of a double-acting
cylinder is to advance even if the pushbutton is only briefly actuated. This signal
storage can be effected either in the power section or in the signal control section of
a circuit.
– Describe how signal storage is devised in the power section or signal control
section respectively.
Signal storage in the A double solenoid valve is to be used for signal storage.
power section Owing to the static friction of the valve piston, the double solenoid valve
maintains its switching position even when the corresponding solenoid
coil is no longer energised.
Signal storage in the By means of a spring-return solenoid valve with self-latching loop .
signal control section The relay coil is energised and a contact closes. Once the ON pushbutton
is released, current continues to flow through the coil via the closed
contact. The relay remains in the actuated position and therefore also the
spring-returned solenoid valve. Actuation of an OFF pushbutton causes the
current to be interrupted. Depending on the configuration of the two
pushbuttons, differentiation is made between dominant setting or
dominant resetting self-latching loops.
Name: Date:
– Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2-
way solenoid valve with manual override, double-acting cylinder) in the event of
– Power failure
– Pressure failure
– Pressure and power failure.
The spring-return solenoid valve switches into The solenoid valve switches into the normal
the normal position, the double-acting cylinder position due to the reduced operating
moves into the retracted end position. The pressure, the double-acting cylinder is without
solenoid valve and consequently the cylinder pressure and assumes an undefined position.
can be switched manually using the manual
override.
Name: Date:
Note
0 means: Pushbutton S1 not actuated, i.e. lamp P1 off
1 means: Pushbutton S1 actuated, i.e. lamp P1 illuminated
S1 P1
Function table
1
S2 P1
Logic symbol
Name: Date:
1A1
1V2 1 1 1V3
2 2
1V1 4 2
1M1
5 3
1
Name: Date:
+24 V 1 2 3
13 12 14 22 24
S1 K1 K1
14 11 21
31
S2
32
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24 .3
32
31 34
42
41 44
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position in the initial position.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised; the changeover contact K1 (connected in the form of a normally open
contact) in current path 2 closes and activates the self-latching loop of relay K1. In
addition, the changeover contact K1 in current path 3 closes and the solenoid coil
1M1 of the 5/2-way solenoid valve 1V1 is energised. The valve 1V1 reverses. The
piston end of cylinder 1A1 is then filled with compressed air whilst the piston rod
side is exhausted. Cylinder 1A1 advances.
Steps 2-3
Actuation of pushbutton S2 (normally closed contact) cancels the self-latching loop
of relay K1. The changeover contact K1 (connected in the form of a normally open
contact) in current path 3 opens and the relay K1 is de-energised. The valve 1V1
reverses via the return spring.
The piston rod end of cylinder is filled with compressed air whilst the piston end is
exhausted. the cylinder returns into the retracted end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
1 Relay
1 Manifold
Equipment list
Name: Date:
A latching relay circuit is required in order to store a signal in the signal control
section.
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Name: Date:
– Complete the electrical circuit diagram so that the self-latching loop is reliably
cancelled via the actuation of a pushbutton S2.
+24 V 1 2 +24 V 1 2
12 14
13 12 14 K1
S1 K1 11
14 11
13 31
S1 S2
31 14 32
S2
32
A1 A1
K1 K1
A2 A2
0V 12
0V 12
11 14 .2 11 14 .2
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44
Electrical circuit diagram; left: Dominant resetting self-latching loop; right: Dominant setting self-latching loop
Name: Date:
– Complete the table and enter the behaviour of the respective valve.
Valve position unchanged/valve is actuated/valve switches to normal position
Set and reset signal shared Valve position Valve is actuated Valve switches to
unchanged normal position
Name: Date:
The function of limit switches and proximity sensors is to acquire information and to
transmit this for signal processing.
These include:
Mechanical position switches (limit switches), magnetic proximity sensors (reed
switches), optical proximity sensors, capacitive proximity sensors, inductive
proximity sensors
Designation Symbol
BK
BU
BK
BU
BK
BU
BK
BU
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B1 BN 1B2 BN
13 12 14 12 14 12 14
BK BK
S1 K1 K2 K3
14 11 11 11
BU BU
22 24
31 K1
S2 21
32
A1 A1 A1
K1 K2 K3 1M1 1M2
A2 A2 A2
0V 12 12 12
11 14 .2 11 14 .7 11 14 .8
22 22 22
21 24 .7 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position in the initial position.
If cylinder 1A1 is in the retracted end position, then the proximity sensor 1B1 is
actuated, and the relay K2 is energised; the changeover contact K2 (connected in the
form of a normally open contact) in current path 7 closes.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be
energised; the changeover contact K1 (connected in the form of a normally open
contact) in current path 2 closes and activates the self-latching loop of relay K1. In
addition the changeover contact K1 (connected in the form of a normally open
contact in current path 7 closes and the solenoid coil 1M1 of the 5/2-way double
solenoid valve 1V1 is energised. The double solenoid valve 1V1 reverses. The rear
chamber of the cylinder 1A1 is now filled with compressed air whilst the front
chamber is exhausted. Cylinder 1A1 advances. As soon as the cylinder 1A1 moves
out of the retracted end position, proximity sensor 1B1 is no longer actuated. This
also causes the changeover contact K2 (connected in the form of a normally open
contact) in current path 7 to open and current no longer flows through the solenoid
coil 1M1. The double solenoid valve nevertheless remains in the righthand switching
position.
Steps 2-n
The proximity sensor 1B2 is actuated when the cylinder reaches the forward end
position and the relay K3 is energised. The changeover contact K3 (connected in the
form of a normally open contact) in current path 8 closes and the solenoid coil 1M2
is energised. This causes the valve 1V1 to return into the initial position and the
cylinder 1A1 to return into the retracted end position. The relay K3 is de-energised
as soon as proximity sensor 1B2 is no longer actuated; the changeover contact K3
(connected in the form of a normally open contact) in current path 8 opens, causing
the coil 1M2 to be de-energised.
Since the electrical latching circuit of relay K1 is still active, the solenoid coil 1M1
receives another switching pulse as soon as the retracted end position is reached so
that the cylinder 1A1 immediately advances again.
Name: Date:
Step n-(n+1)
The oscillating movement of cylinders 1A1 can be interrupted by means of pressing
pushbutton S2 (normally closed contact), thereby cancelling the self-latching loop of
relay K1. The cylinder moves into the retracted end position and remains there.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
3 Relay
1 Manifold
Equipment list
Name: Date:
In contrast with limit switches proximity sensors are switched contactlessly and
without an external mechanical actuating force.
– Describe the design and function of a magnetic proximity sensor (reed switch).
Name: Date:
As regards polarity there are two different designs of electronic proximity sensors,
i.e. PNP or NPN
PNP NPN
In the case of negative switching sensors a In the case of positive switching sensors, zero
supply voltage is applied at the output in the voltage is applied at the output in the absence of a
absence of a part within the response range of part within the response range of the sensor. The
the sensor. The approaching of a workpiece or approaching of a workpiece or machine part causes
machine part causes the output to switch to 0V the output to switch so that supply voltage is
voltage. applied.
Name: Date:
With a PE converter, a pneumatic pressure signal switches an electrical signal generator (generally in
the form of a changeover switch); consequently a pneumatic input signal is output as an electrical
signal.
If the switching pressure is adjustable, this is known as a pressure sensor.
Name: Date:
Pressure sensors can be divided into two groups whereby differentiation is made
between:
• Pressure sensors with mechanical contact (mechanical principle of action)
• Pressure sensors with electronic switching
(electronic principle of action)
– Describe the purpose and function of the pressure sensor shown below.
Name: Date:
– Choose which proximity sensors meet the specified requirements and explain
your reasons for this.
Inductive proximity sensor Both proximity sensors operate contactlessly and without
or mechanical actuation. Both proximity sensors are insensitive
magnetic proximity sensor to dirt. Since the trip cam is made of metal, both inductive as
well as magnetic proximity sensors are feasible.
Name: Date:
1A1
1B1 1B2
1V2 1 1 1V3
1B3
p
2 2
1V1 4 2
1M1 1M2
5 3
1
Name: Date:
+24 V 1 2 3 4 5 6 7 8
A1 A1 A1
K1 K2 K3 1M1 1M2
A2 A2 A2
0V 12 12 12
11 14 .7 11 14 .8 11 14 .8
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Initial position
Cylinder 1A1 is in the retracted end position in the initial position.
The proximity sensor 1B1 is actuated if the cylinder 1A1 is in the retracted end
position. This causes the relay K1 to be energised and the changeover contact K1
(connected in the form of a normally open contact) in current path 7 to be closed.
Steps 1-2
Actuation of pushbutton S1 (normally open contact) causes the solenoid coil 1M1 of
the 5/2-way double solenoid valve 1V1 to be energised. The double solenoid valve
1V1 reverses and cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of
the retracted end position, the proximity sensor 1B1 is no longer actuated. This
causes the changeover contact K1 (connected in the form of a normally open
contact) in current path 7 to open and the solenoid coil 1M1 is no longer current-
carrying. The double solenoid coil nevertheless remains in the righthand switching
position.
Steps 2-3
When the cylinder reaches the forward end position, the proximity sensor 1B2 is
actuated and the relay K2 energised. The changeover contact K2 (connected in the
form of a normally open contact) in current path 8 closes. In the meantime, the
pressure sensor 1B3 measures the pressure applied at cylinder 1A1. The pressure
sensor (programmed as a normally open contact) switches if the pressure is
identical or greater than the set required value and the relay K3 is energised; the
changeover contact K3 (connected in the form of a normally open contact) in current
path 8 closes and the solenoid coil 1M2 is now energised. This causes the valve 1V1
to reverse and the cylinder 1A1 to move into the retracted end position.
As soon as the proximity sensor 1B2 is no longer actuated, the relay K2 is de-
energised and the changeover contact K2 (connected in the form of a normally open
contact) opens.
The pressure sensor (programmed as normally open contact) switches off if the set
required value is not met and the relay K3 is de-energised; the changeover contact
K3 (connected in the form of a normally open contact) in current path 8 opens
thereby also causing the coil 1M2 to be de-energised.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
1 Pressure sensor
3 Relay
1 Manifold
Equipment list
Name: Date:
S1
1 2 3 4=1
1
1B2
1A1
0
2B2
1
2A1
0
Displacement-step diagram
Name: Date:
– Design the pneumatic and electrical circuit diagrams for the pallet loading
station.
1A1 2A1
1B2 2B2
2 2 1
1V1 4 2 2V1 2
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Initial position
Cylinders 1A1 and 2A1 are in the retracted end position in the initial position.
Steps 1-2
Actuation of pushbutton S1(normally open contact) causes the relay K3 to be
energised. The changeover contact K3 (connected in the form of a normally open
contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid coil 1V1 is
energised. The double solenoid valve 1V1 reverses and the cylinder 1A1 advances.
As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay
K3 is de-energised and the changeover contact K3 (connected in the form of a
normally open contact) opens.
Consequently, the coil 1M1 is also de-energised.
Steps 2-3
As soon as the cylinder 1A1 reaches the forward end position, the proximity sensor
1B2 switches and the relay K1 is energised. The changeover contact K1 (connected
in the form of a normally open contact) in current path 8 closes and the solenoid coil
2M1 of the 3/2-way solenoid valve 2V1 is energised. The valve 2V1 reverses and the
cylinder 2A1 advances.
Steps 3-4
The proximity sensor 2B2 is actuated when the cylinder 2A1 reaches the forward end
position and the relay K2 is energised. The changeover contact K2 (connected in the
form of a normally open contact) in current path 7 closes. The solenoid coil 1M2 is
now energised, thereby causing the valve 1V1 to reverse and the cylinder 1A1 to
move into the retracted end position.
Relay K1 is de-energised as soon as the cylinder 1A1 moves out of the forward end
position. The normally open contact K1 in current path 8 opens and the solenoid coil
2M1 is de-energised. The return spring switches the valve 2V1 into the initial
position again and the cylinder 2A1 moves into the retracted end position.
Name: Date:
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
1 Cylinder, double-acting
1 Cylinder, single-acting
3 Relay
1 Manifold
Equipment list
Name: Date:
1A1 2A1
1B2 2B2
2 2 1
1V1 4 2 2V1 2
Name: Date:
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Line interruption in signal line of sensor 2B2, current path 4(e.g. cable break or loose connection)
Line interruption in earthing wire of 1M2, current path 7 (e.g. cable break or loose connection), valve
coil 1M2 faulty
Line interruption in earthing wire of relay K2, current path 4 (e.g. cable break or loose contact), relay
K2 faulty
Line interruption in current path 7, supply line of relay contact 14 (relay K2) or supply line of relay
contact 11 (relay K2) after valve coil 1M2 (e.g. cable break or loose contact)
Name: Date:
A cable break occurs at the points marked in the circuit shown below.
– Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2 BN 2B2 BN
13 12 14 12 14 12 14
BK BK
S1 K3 K2 K1
14 11 11 11
BU BU
A1 A1 A1
K1 K2 K3 1M1 1M2 2M1
A2 A2 A2
0V 12 12 12
11 14 .8 11 14 .7 11 14 .6
22 22 22
21 24 21 24 21 24
32 32 32
31 34 31 34 31 34
42 42 42
41 44 41 44 41 44
Name: Date:
Break in earthing wire of Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Relay K1 is not energised => Relay contact in
relay K1, current path 2 current path 8 (changeover contact, connected in the form of normally open contact) does not switch =>
Piston rod of cylinder 2A1 does not move into the forward end position (remains retracted), sensor 2B2 is
not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
Break in signal wire of Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder2A1 moves into the
sensor 2B2, forward end position, sensor 2B2 is actuated => Relay K2 is not energised => Relay contact in current path 7
current path 4 (changeover contact, connected in the form of a normally open contact) does not switch => Piston rod of 1A1
and piston rod of cylinder 2A1 remain advanced.
Break in supply line of relay Current path 5 is not closed, relay K3 is not energised, no reaction in response to start signal => Piston rod
K3, current path 5 of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted.
Break in supply line of relay Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 moves into the
contact 14 forward end position, sensor 2B2 is actuated => Relay K2 is energised, relay contact in current path 7
(relay K2), current path 7 (changeover contact, connected in the form of a normally open contact) switches, but valve coil 1M2 is not
energised due to cable break => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced.
Break in earthing wire 2M1, Piston rod of cylinder 1A1 advances => Sensor 1B2 is actuated => Relay K1is energised, relay contact in
current path 8 current path 8 (changeover contact, connected in the form of a normally open contact) switches, but valve
coil 2M1 is not energised due to cable break => Piston rod of cylinder 2A1 remains retracted, piston rod of
1A1 remains advanced.
Name: Date:
Displace sensor 1B2 on cylinder Sensor 1B2 at cylinder Piston rod of cylinder 1A1 advances, sensor 1B2 is briefly actuated =>
1A1 in the retracted end position 1A1 maladjusted Piston rod of cylinder 2A1 does not move up to the forward end position,
direction sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains
advanced since 1M2 is not actuated.
Remove sensor 1B2 signal line or Cable break in signal line Piston rod of cylinder 1A1 advances => No sensor signal, i.e. sensor 1B2
displace sensor at forward end of sensor 1B2, or sensor is not actuated => Piston rod of cylinder 2A1 remains retracted, piston
position maladjusted rod of cylinder 1A1 remains advanced.
Remove sensor 2B2 signal line or Cable break in signal line Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston
displace sensor at forward end of sensor 2B2, or sensor rod of cylinder 2A1 advances into the forward end position, no sensor
position maladjusted signal, i.e. sensor 2B2 is not actuated => Piston rod of cylinder 1A1 and
piston rod of cylinder 2A1 remain advanced.
Interrupt current path 2 (e.g. Cable break in earthing Piston rod of cylinder 1A1 advances => Piston rod of cylinder 2A1
earthing wire of relay K1, signal wire of 2M1, K1 or supply remains retracted since current path 2 or current path 8 is interrupted.
line or current path 8, e.g. supply lines of relay contact
lines of relay contact 14 or relay 14/11 (relay K1)
contact 11 (relay K1), remove
earthing wire of 2M1
Interrupt earthing wire of relay K2, Cable break in earthing Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 advance and
current path 4 or current path 7, wire of 1M2, K2 or supply remain in the forward end position.
or remove relay K2 or supply lines lines of relay contact
of relay contact 14 or relay contact 14/11 (relay K2)
11 (relays K2), earthing wire of
1M2
Interrupt earthing wire of relay K3, Cable break in earthing No reaction to start signal => Piston rod of cylinder 1A1 and piston rod of
current path 5 or current path 6 wire 1M1, K3 or supply cylinder 2A1 remain retracted.
Remove 1M1 or K3 or supply line line of relay contact 14 at
of relay contact 14 at K3 K3
Name: Date:
It is important to make sure that trainees proceed systematically during fault finding.
Alternative
If the circuit of exercise 11 is not available fully assembled, it is also possible to
carry out the fault finding theoretically:
• The trainer explains the fault („cylinder 1A1 advances, the circuit then comes to a
stop.“)
• Trainees then localise the fault with the help of the function chart.
• Trainees draw up a list of potential causes of faults and describe how they
proceed during the fault finding (where do you need to measure, what needs to
be checked).
All components of the equipment set for the technology package TP201 are stored in
an organiser within a Systainer. The organiser also serves as a drawer insert for use
in conjunction with our range of laboratory furniture.
Three variants are available for the assembly of equipment on the profile plate:
Variant A
A latching system, without auxiliary means, clamping mechanism using a lever and
spring, adjustable in the direction of the slot, for lightweight non-loadable
components.
Variant B
A rotary system, without auxiliary means, knurled nut with locking disc and T-head
bolts, vertical or horizontal alignment, for medium weight loadable components .
Variant C
A screw system, with auxiliary means, socket head screw with T-head bolt, vertical
and horizontal alignment, for heavy loadable components and equipment which is
rarely released from the profile plate.
The proven ER units on plug-in board can be attached to the profile plate with
adapters.
In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide
is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back
whereby the component can be removed from or attached to the profile plate.
Components are aligned along the slot and can be moved in the direction of the slot.
With variant B, components are attached to the profile plate by means of a T-head
bolt and blue knurled nut. A locking disc serves to fix the device in position, which
can be secured in any 90° direction. Devices can thus be mounted on the profile
plate either lengthwise or diagonally to the slot.
Once the desired locking disc position is set, the device is mounted on the profile
plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in
the slot by 90° owing to thread friction. The component is pressed against the profile
plate by further turning the knurled nut.
Plastic tubing The polyurethane tubing is particularly flexible and kink resistant.
Technical data
Pneumatics
Outer diameterr 4 mm
Subject to change
Design The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic
retainer. The unit is mounted on the profile plate via quick release detent system
with two blue trip grip nuts (mounting alternative "B").
Function The piston rod of the single-acting cylinder moves into the forward end position
through the supply of compressed air. When the compressed air is switched off, the
piston is returned to the retracted end position via a return spring.
The magnetic field of a permanent magnet, which is attached to the cylinder piston,
actuates the proximity switches.
Piston diameter 20 mm
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152888
Double-acting cylinder
Design The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic
retainer. The unit is mounted on the profile plate via a quick release detent system
with two triple grip nuts (mounting alternative "B").
Function The piston rod of the double-acting cylinder is reversed by means of alternating
supply of compressed air. End position cushioning at both ends prevents a sudden
impact of the piston on the cylinder housing. The end position cushioning can be
adjusted by means of two regulating screws.
The magnetic field of a permanent magnet attached to the cylinder piston actuates
the proximity switches.
Piston diameter 20 mm
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152896
Manifold
Design The manifold with eight self-sealing push-in fittings is screwed on to a universal
plate. The unit is mounted on the profile plate via a quick release detent system with
blue lever (mounting alternative "A").
Function The manifold with a common P-supply enables a control system to be supplied with
compressed air eight individual connections.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 07/2005
162241
Relay, 3-off
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
12 14 22 24 32 34 42 44
A1
A2 11 21 31 41
Design This component consists of three relays with connections and two bus-bars for the
power supply. All electrical connections are in the form of 4 mm sockets. The unit
can be mounted in a mounting frame or on the profile plate using four plug-in
adapters.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/4
162241
Relay, 3-off
2 3
A1 A2 4 2 1
7 6
Function The relay consists of a coil with a core (1) and winding (3) with connection lugs (7),
an armature (4), a return spring (2) and a contact assembly with four changeover
contacts (5) and connection lugs (6). When power is applied to the coil connections,
current flows through the winding, creating a magnetic field. The armature is pulled
onto the coil core and the contact assembly is actuated. Electrical circuits are
opened or closed via this assembly.
When the electrical current is removed, the magnetic field collapses and the
armature and contact assembly are returned to their original position by a return
spring.
Note The switching status of the relays is indicated by LEDs, which are protected against
incorrect polarity.
The four changeover contacts of the contact assembly can be used as normally-open
contacts (1), normally-closed contacts (2) or changeover contacts (3).
2/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
162241
Relay, 3-off
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
+24 V 1 2 +24 V 1 2
A1 12 14 A1 12 14
K1 K1
A2 11 A2 11
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 3/4
162241
Relay, 3-off
Voltage 24 V DC
Pichup time 10 ms
Drop-off time 8 ms
Electromagnetic compatibility
4/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
162242
Signal input plate, electrical
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
13 23 31 41
14 24 32 42
Design This component consists of two illuminated pushbuttons in the form of momentary-
contact switches and one illuminated pushbutton in the form of a detented switch.
All electrical connections are in the form of 4 mm safety connectors. The unit can be
mounted in a mounting frame or on the profile plate using four plug-in adapters.
Function The illuminated pushbutton in the form of a detented switch consists of a contact
assembly with two normally-open contacts and two normally-closed contacts,
together with a colourless transparent pushbutton cap with a miniature lamp. The
contact assembly is actuated by pressing this cap. Electrical circuits are opened or
closed via the contact assembly. When the cap is released, the switching status is
maintained. The contact assembly is returned to its initial position by pressing the
pushbutton a second time.
The illuminated pushbuttons in the form of momentary-contact switches consist of
a contact assembly with two normally-open contacts and two normally-closed
contacts, together with a colourless transparent pushbutton cap with a miniature
lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are
opened or closed via the contact assembly. When the cap is released, the contact
assembly returns to its initial position.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
162242
Signal input plate, electrical
Note When power is applied to the connections of the visual indicator, the switching
status is displayed by the built-in miniature lamp in the pushbuttons.
+24 V 1 2
13 12 14
S1 K1
14 11
A1
K1 1M1
A2
0V 12
11 14 .2
22
21 24
32
31 34
42
41 44
Voltage 24 V DC
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
178577
Proximity sensor, optical
Design The optical proximity sensor with LED and electrical connections is assembled on a
polymer assembly base. The electrical connection is effected by means of safety
connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a
quick release detent system with blue triple grip nut (mounting alternative “B”).
Function Optical proximity sensors consist of two main modules, the emitter and the receiver.
In the case of diffuse sensor, these are built into one housing. The emitter of the
diffuse sensor emits a pulsating, red light which is within the visible spectral range.
The object to be detected reflects part of the light emitted. This light is detected by a
semiconductor device in the receiver which is also built into the sensor housing and
causes a change in the switching status.
The object to be detected may be reflective, matt, transparent or opaque. All that is
needed is for a sufficiently high proportion of light to be reflected directly or
diffusely.
The operational switching distance may be varied by means of a potentiometer. The
proximity sensor has a PNP output, i.e. the signal line is switched to the positive
potential in the switched status. The switch is designed as a normally closed
contact. The connection of the load takes place between the signal output of the
proximity sensor and the load. The switching status is indicated by a yellow LED. The
sensor is protected against polarity reversal, overload and short circuit.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
178577
Proximity sensor, optical
+24V-
BN +
B
BK
BU
Note The correct polarity of the applied voltage is necessary for proper functioning. The
connections for the operating voltage are colour coded as follows: red for positive,
blue for negative and black for the signal output. The load is connected to the
switching output and the negative terminal of the current supply.
Switching voltage 10 – 30 V DC
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
183322
Limit switch, electrical, actuated from the left
2 4
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design A microswitch with roller lever and electrical connections is installed in a plastic
housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant “B”).
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
183322
Limit switch, electrical, actuated from the left
Voltage 24 V DC
Actuation force 5N
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
183345
Limit switch, electrical, actuated from the right
2 4
The two electrical limit switches, order no. 183322 for actuation from the left and
order no. 183345 for actuation from the right, have the same symbol in the circuit
diagram.
Design A microswitch with roller lever and electrical connections is installed in a plastic
housing. The electrical connection is effected by means of safety connectors or via a
3-pin plug socket. The component is mounted on the profile plate using the rotary
system by means of two blue grip nuts (mounting variant “B”).
© Festo Didactic GmbH & Co. KG, 09/2005 Subject to change 1/2
183345
Limit switch, electrical, actuated from the right
Voltage 24 V DC
Actuation force 5N
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 09/2005
539757
Pressure sensor with display
Design The pressure sensor with display is screwed onto the adapter plate plate. The unit is
attached via the grid system with the blue lever (assembly variant „A“).
Function The pressure sensor is a piezoresistive relative pressure transducer with integrated
amplifier and built-in temperature compensation. The pressure to be measured is
transferred onto a silicone coated piezoresistive element. The signal change
generated therein is output as a voltage or switching signal at the connector plug via
an intergrated amplifer.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
539757
Pressure sensor with display
+24V-
BN
B
p BK
BU
Note The polarity of the applied voltage is to be observed for the correct functioning of
the device. The connections for the operating voltage are to be identified by colour:
Red for positive and blue for negative. The signal output is black. The load is to be
connected to the switch output and to the negative pole of the power supply.
Analogue output 0 to 10 V
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
539773
One-way flow control valve
1 2
Design The adjustable one-way flow control valve is screwed into the function plate,
incorporating a straight push-in fitting. The unit is slotted into the profile plate via a
quick release detent system with a blue lever (mounting alternative “A”).
Function The one-way flow control valve consists of a combination of a flow control valve and
a non-return valve.
The non-return valve blocks the flow of air in one direction, whereby the air flows via
the flow control valve. The throttle cross section is adjustable by means of a knurled
screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the
direction of flow control on the housing. In the opposite direction, the air flow is
unrestricted via the non-return valve.
© Festo Didactic GmbH & Co. KG, 06/2005 Subject to change 1/1
© Festo Didactic GmbH & Co. KG, 06/2005
539776
2 x 3/2-way solenoid valve with LED, normally closed
1M1
1 3
1M1
Design This 3/2-way single solenoid valve with push-in fittings is attached to a function
plate which is equipped with a P port and silencer. The two electrical connections
are equipped with safety connectors. The unit is mounted on the profile plate using
a quick release detent system with a blue lever (mounting alternative "A").
Function The solenoid valve is reversed when voltage is applied to the solenoid coil (1 2)
and brought back into its initial position (1 0) by a return spring when the signal
is removed. The switching status is displayed via an LED in the terminal housing. The
valve is equipped with a manual override.
Note The solenoid coil is characterised by very low power consumption and low heat
generation. The electrical connection incorporates protection against incorrect
polarity for the LED and a protective circuit.
© Festo Didactic GmbH & Co. KG, 09/2005 Subject to change 1/2
539776
2 x 3/2-way solenoid valve with LED, normally closed
Electrical
Voltage 24 V DC
Connection M8x1 central plug, cable with socket and 4 mm safety plugs
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 09/2005
539777
5/2-way single solenoid valve with LED
4 2
1M1
5 1 3
1M1
Design This 5/2-way single solenoid valve with push-in fittings is bolted onto a function
plate which is equipped with a P port and silencer. The two electrical connections
are equipped with safety connectors. The unit is mounted on the profile plate using
a snap-lock system with a blue lever (mounting variant "A").
Function The solenoid valve is reversed when voltage is applied to the solenoid coil (1 4)
and brought back into its initial position (1 2) by a return spring when the signal
is removed. The switching status is shown by an LED in the terminal housing. The
valve is equipped with a manual override.
Note The solenoid coil is characterised by very low power consumption and low heat
generation. The electrical connection incorporates protection against incorrect
polarity for the LED and a protective circuit.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
539777
5/2-way single solenoid valve with LED
Electrical
Voltage 24 V DC
Connection M8x1 central plug, cable with socket and 4 mm safety plugs
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
539778
5/2-way double solenoid valve with LED
4 2
1M1 1M2
5 1 3
1M1 1M2
Design This 5/2-way double solenoid valve with push-in fitting is bolted onto a function
plate which is equipped with a P port and silencer. The four electrical connections
are equipped with safety connectors. The unit is mounted on the profile plate using
a snap-lock system with a blue lever (mounting variant "A").
Function The double solenoid valve is reversed when voltage is applied to a solenoid coil and
remains in this switching position after the signal is removed until an opposed signal
is applied. The presence of switching signals is shown by the LEDs in the terminal
housings. The valve is equipped with a manual override.
Note The solenoid coil is characterised by very low power consumption and low heat
generation. The electrical connections incorporate protection against incorrect
polarity for the LEDs and protective circuits.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
539778
5/2-way double solenoid valve with LED
Electrical
Voltage 24 V DC
Connection M8x1 central plug, cable with socket and 4 mm safety plugs
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
540691
Start-up valve with filter control valve
2
3
1
2
3
Design The filter regulator with pressure gauge, on/off valve, push-in fitting and quick
coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a
metal bowl guard. The unit is mounted on the profile plate by means of cheese head
screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling
socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.
Function The filter with water separator cleans the compressed air of dirt, pipe scale, rust and
condensate.
The pressure regulator adjusts the compressed air supplied to the set operating
pressure and compensates for pressure fluctuations. An arrow on the housing
indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The
pressure gauge shows the preset pressure. The on/off valve exhausts the entire
control. The 3/2-way valve is actuated via the blue sliding sleeve.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
540691
Start-up valve with filter control valve
Note When constructing a circuit, please ensure that the filter regulator is installed in the
vertical position. The pressure regulator is fitted with an adjusting knob, which can
be turned to set the required pressure. By sliding the adjusting knob towards the
housing, the setting can be locked.
Connection Coupling plug for coupling socket G1/8 QS push-in fitting for
plastic tubing PUN 6 x 1
* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar),
Differential pressure: 100 kPa (1 bar).
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005
540695
Proximity sensor, electronic, with cylinder mounting
Design The proximity sensor consists of the sensor, mounting kit and cable . The cable is
equipped with a socket and three jack plugs.
Function This proximity sensor emits an electrical signal when approaching a magnetic field
(e.g. permanent magnet on a cylinder piston). The electrical connections are
moulded into the cable. The switching status is indicated via an LED. The yellow LED
is illuminated when actuated.
+24V-
BN +
B
BK
BU
Note The polarity of the applied voltage is to be observed for the correct functioning of
the device. The wires inside the socket cable must therefore be allocated by colour:
Red (BN) for positive, blue (BU) for negative and black (BK) for the signal output. In
this case, the load (relay) is connected to the sensor and to the negative pole. The
switch is protected against reverse polarity but not against short circuit.
© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/2
540695
Proximity sensor, electronic, with cylinder mounting
Switching voltage 10 to 30 V DC
Electromagnetic compatibility
2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005